Flexible rework device

ABSTRACT

A rework device in form of a flexible circuit is provided in order to repair a printed circuit assembly. The printed circuit assembly includes one or more through vias and interconnections. The flexible circuit includes a lead in portion and a tail portion. The flexible circuit also includes a first distended head portion proximal to the lead in portion and a second distended head portion proximal to the tail portion. Further, the second distended head portion is connected to the first distended head portion through a coverlay portion. The flexible circuit provided is adapted to be threaded through a through via to repair the printed circuit assembly.

FIELD OF INVENTION

The present disclosure relates to a printed circuit assembly. Moreparticularly the present invention relates to a rework device thatenables repair or rework of a defective printed circuit assembly.

BACKGROUND

Printed circuit assemblies are used for numerous electronic applicationsthese days. The printed circuit assemblies contain a number ofinterconnections, wirings, through vias and plated through holesextending from external connections on one surface of the printedcircuit assembly to wirings and connections on the opposite surface.

Often the printed circuit assemblies because of incorrect design ormanufacturing errors end up carrying defects. The defects in the printedcircuit assemblies may include undesirable short circuits, open circuitsor misrouted traces. Even a single defect in one of a plurality ofconnections on the printed circuit assemblies can lead to the entireassembly being deemed defective. The defect in the connection andassociated through vias must be either repaired or completely replacedelse the defective printed circuit assemblies will have to be discarded.

There are a few known solutions for repairing of defective printedcircuit assemblies. One solution being deep deletion of the defectivethrough via. The deleted through via is then filled with an epoxysolution and then a new through via is drilled and the connections aresoldered again.

The problem with such a solution is that additional wires need to beadded to the printed circuit assembly. Also, since the printed circuitassembly have a plurality of interconnections; it becomes difficult tosolder new interconnections in such a tight package of the plurality ofinterconnections. Such soldering may also lead to short circuits andsome other additional defects in the printed circuit assemblies.

Also, in cases of Land Grid Array (LGA) applications, multipleinterposers are used in a stacked structure to repair a defective LGA.The stacked structure may lead to overcrowding of interconnections inthe LGA and may lead to short circuits within the LGA.

Therefore, in light of above discussion there is a need of a solutionthat facilitates easy and safe rework of defective printed circuitassemblies.

BRIEF SUMMARY

The present invention provides a flexible circuit useful for printedcircuit assembly repair. The present invention overcomes thedisadvantages in conventional systems for repair of printed circuitassemblies. The present invention entails better yield advantages.

Another object of the present invention is to provide a flexible circuitthat enables improved reliability and reduced costs of printed circuitassembly rework.

Another object of the present invention is to provide a flexible circuitthat provides insertion of additional function or design options duringreworking of defects in printed circuit assemblies.

Another object of the invention is to provide additional wiringcapability in localized high wiring density area of a printed circuitassembly, without adding additional wiring layers across entire printedcircuit assembly board.

Another object of the present invention is to provide an improvedprobing technique using the flexible circuit of the present invention.

Yet another object of the present invention is to enable a flexiblecircuit to make interconnections in an LGA without adding an extrainterposer.

In one embodiment of the invention, a rework device in form of aflexible circuit is provided in order to repair a printed circuitassembly, the printed circuit assembly including one or more throughvias and interconnections. The flexible circuit is adapted to bethreaded through a through via. The flexible circuit is a planarstructure that includes a lead in portion and a tail portion. Theflexible circuit also includes a first distended head portion proximalto the lead in portion and a second distended head portion proximal tothe tail portion. Further, the second distended head portion isconnected to the first distended head portion through a coverlay portionwhich may be of varying lengths, such that the length of the coverlayportion is substantially equal to a depth of the through via.

In an another embodiment of the invention, a rework device in form of aflexible circuit is provided in order to repair a printed circuitassembly, the printed circuit assembly including one or more throughvias and interconnections. The flexible circuit is adapted to bethreaded through a through via. The flexible circuit includes a lead inportion and a tail portion. The flexible circuit also includes a firstdistended head portion proximal to the lead in portion and a seconddistended head portion proximal to the tail portion. Further, the seconddistended head portion is connected to the first distended head portionthrough a coverlay portion, such that the coverlay portion includes alooped segment. In embodiments of the invention, the looped segment canbe a coiled segment or a helical segment as per the different use theflexible circuit needs to be put to.

In yet another embodiment of the invention, a rework device in form of aflexible circuit is provided in order to repair a printed circuitassembly, the printed circuit assembly including one or more throughvias and interconnections. The flexible circuit is adapted to bethreaded through a through via. The flexible circuit is structured toinclude multiple branches. The multiple branches in the flexible circuitis configured to be threaded through a through via. The flexible circuitincludes a plurality of lead in portions and a plurality of tailportions. Further, the flexible circuit also includes a plurality offirst distended head portions corresponding to the plurality of lead inportions and a plurality of second distended head portions correspondingto the plurality of tail portions. The plurality of second distendedhead portions and the plurality of first distended head portions beingthrough corresponding coverlay portions.

In yet another embodiment of the present invention, a debug probingdevice is provided. The debug probing device being configured to debugprobing of a defective printed circuit assembly. The debug probingincludes a plurality of leader threads connected to the debug probingdevice. Further each of the plurality of leader threads has a connectedrework device that can be threaded into through vias of a defectiveprinted circuit assembly.

These and other exemplary embodiments, features and advantages of thepresent invention will be described or become apparent from thefollowing detailed description of exemplary embodiments, which is to beread in connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The features of the present invention, which are believed to be novel,are set forth with particularity in the appended claims. The inventionmay best be understood by reference to the following description, takenin conjunction with the accompanying drawings. These drawings and theassociated description are provided to illustrate some embodiments ofthe invention, and not to limit the scope of the invention.

FIG. 1 is a top view of a portion of an exemplary printed circuitassembly with two circular contact pads, in accordance with anembodiment of the present invention;

FIG. 2 is a side view of the printed circuit assembly of FIG. 1illustrating through vias and conductive layers, in accordance with anembodiment of the present invention;

FIG. 3 is a diagrammatic illustration of an exemplary flexible circuit,in accordance with an embodiment of the present invention;

FIG. 4 is a diagrammatic illustration of an exemplary flexible circuithaving a plurality of branches, in accordance with an embodiment of thepresent invention;

FIG. 5 is a diagrammatic illustration of another exemplary flexiblecircuit having a plurality of branches, in accordance with anotherembodiment of the present invention;

FIG. 6 is a diagrammatic illustration of exemplary flexible circuitshaving different coverlay portions, in accordance with anotherembodiment of the present invention;

FIGS. 7 a, 7 b and 7 c are diagrammatic illustration of exemplary stagesof repairing of a printed circuit assembly using an exemplary flexiblecircuit, in accordance with an embodiment of the present invention;

FIG. 8 is a diagrammatic illustration of an exemplary debug probingdevice used for probing a printed circuit assembly, in accordance withan embodiment of the present invention; and

FIG. 9 is a diagrammatic illustration of a stage of using a debugprobing device for probing a printed circuit assembly, in accordancewith another embodiment of the present invention.

Those with ordinary skill in the art will appreciate that the elementsin the figures are illustrated for simplicity and clarity and are notnecessarily drawn to scale. For example, the dimensions of some of theelements in the figures may be exaggerated, relative to other elements,in order to improve the understanding of the present invention.

There may be additional structures described in the foregoingapplication that are not depicted on one of the described drawings. Inthe event such a structure is described, but not depicted in a drawing,the absence of such a drawing should not be considered as an omission ofsuch design from the specification.

DETAILED DESCRIPTION

Before describing the present invention in detail, it should be observedthat the present invention utilizes a combination of method steps andapparatus components related to a rework device for repairing printedcircuit assemblies. Accordingly the apparatus components and the methodsteps have been represented where appropriate by conventional symbols inthe drawings, showing only specific details that are pertinent for anunderstanding of the present invention so as not to obscure thedisclosure with details that will be readily apparent to those withordinary skill in the art having the benefit of the description herein.

While the specification concludes with the claims defining the featuresof the invention that are regarded as novel, it is believed that theinvention will be better understood from a consideration of thefollowing description in conjunction with the drawings, in which likereference numerals are carried forward.

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which can be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the present invention in virtually anyappropriately detailed structure. Further, the terms and phrases usedherein are not intended to be limiting but rather to provide anunderstandable description of the invention.

The terms “a” or “an”, as used herein, are defined as one or more thanone. The term “another”, as used herein, is defined as at least a secondor more. The terms “including” and/or “having” as used herein, aredefined as comprising (i.e. open transition). The term “coupled” or“operatively coupled” as used herein, is defined as connected, althoughnot necessarily directly, and not necessarily mechanically.

The present invention, according to preferred embodiments, providesrework device in form of a flexible circuit for repair or rework of aprinted circuit assembly including of one or more through vias, suchthat the flexible circuit is configured to be threaded through a throughvia of the printed circuit assembly.

Referring to FIG. 1, there is shown a top view of a portion of anexemplary printed circuit assembly 100, including but not limited to aprism to prism flex board, having two contact pads 102 and 104. The twocontact pads 102 and 104 are electrically coupled to two through via 106and 108 respectively. A “through via” is a plated hole that connects oneor more conductive pathways on one surface of a circuit board, forexample the printed circuit assembly 100, to conductive pathways onopposite surfaces of the circuit board, for example the printed circuitassembly 100.

Moving on, in FIG. 2, there is illustrated a side view of the printedcircuit assembly 100. Each of the through vias 106 and 108 is shown toconnect an upper surface 202 of the printed circuit assembly 100 andtravel down to a bottom surface 204 of the printed circuit assembly 100.Further, each of the through vias 106 and 108 are illustrated as a holethat is drilled or formed in the printed circuit assembly 100. Thethrough vias 106 and 108 provide electrical communication betweendifferent elements placed on the printed circuit assembly.

Referring to FIG. 3, there is illustrated an exemplary rework device inthe form of a flexible circuit 300, that can be used in rework or repairof a printed circuit assembly, for example the printed circuit assembly100. The flexible circuit 300 has a planar structure and includes a leadin portion 302, a tail portion 304, a first distended head portion 306,a second distended head portion 308, a coverlay portion 310 and analignment portion 312. In an embodiment, the lead in portion 302 and thetail portion 304 can be a detachable portion.

Coverlay portion 310 is a solid, tack-free film comprising one or morelayers, each of which is formed from one or more flexible dielectricadhesive polymers. As used herein, “polymer” includes homopolymers,co-polymers, terpolymers, etc. Preferably, coverlay 310 comprises asingle layer formed from one dielectric adhesive polymer or from amixture of dielectric adhesive polymers.

Further it should be appreciated that in the figure, though the flexiblecircuit is shown to include only one lead in portion 302, one tailportion 304, one first distended head portion 306, one second distendedhead portion 308, one coverlay portion 310 and one alignment portion312, other embodiments of the present invention may include more thanone such elements, without deviating from the scope of the presentinvention.

Through the lead in portion 302, a leader thread can enter and guide theflexible circuit 300 to be threaded through a through via. The flexiblecircuit 300 enters a through via from the lead in portion 302. The firstdistended head portion 306 is proximal to the lead in portion 302 andthe second distended head portion 308 is proximal to the tail portion304. While reworking, the first distended head portion 306 emerges froma bottom surface of a through via through which the flexible circuit 300has been threaded. The second distended head portion 308 remains on theopposite surface of the through via when the flexible circuit 300 hasbeen threaded. The first distended head portion 306 and the seconddistended head portion 308 are so structured that they substantiallyconform to the two holes on the two surfaces of the through via. In anembodiment, the first distended head portion 306 and the seconddistended head portion 308 may be laminated with, but not limited to, apressure sensitive adhesive, an epoxy, a thermoset or any other adhesiveto respective surfaces of the printed circuit assembly 100.

Moving on, the first distended head portion 306 and the second distendedhead portion 308 of the flexible circuit 300 are connected using thecoverlay portion 310. The arrangement of the first distended headportion 306, the second distended head portion 308 and the coverlayportion 310 is such that after reworking there is no perceptibleprotrusion in the printed circuit assembly. This is ensured by keepingthe length of the coverlay portion 310 substantially equal to that of adepth of the through via. This reworking process will be explained inmore detail in association with FIGS. 7 a, 7 b and 7 c.

The flexible circuit 300 also includes the alignment portion 312 that isconfigured to properly align the flexible circuit 300 on the printedcircuit assembly during repair or rework process.

In an embodiment, the breadth of the coverlay portion 310 may be atleast 0.03 inches, preferably they may vary from 0.04 inches to 0.08inches. However, it should be appreciated that in other embodiments ofthe invention, other dimensions as suitable for reworking of the printedcircuit assembly can also be used without deviating from the scope ofthe invention.

Similarly, dimensions of the first distended head portion 306 and thesecond distended head portion 308 may be at least 0.01 inches,preferably they may range from 0.02 inches to 0.03 inches. Inembodiments, the first distended head portion 306 and the seconddistended head portion 308 may be in the form of a spherical or circularbulbous structure having a diameter in the mentioned range. However, itshould be appreciated that in other embodiments of the invention, otherdimensions as suitable for reworking of the printed circuit assembly canalso be used without deviating from the scope of the invention.

In other embodiments, the flexible circuit 300 may be substantiallycompletely or at least partially covered with a suitable kapton or somesimilar purpose material layer running from the lead in portion 302 upto the tail portion 304. In an embodiment, the kapton layer may be madeup of, but not limited to a nickel based material, a ferrous basedmaterial and a gold based material. In an embodiment, the kapton layermay be a solder leveling or any other metal based platings

Moving on, in FIG. 4 there is depicted a flexible circuit 400 accordingto another embodiment of the present invention. The flexible circuit 400is shown to include two separate branches and each branch has separateelements of a flexible circuit. For example, the flexible circuit 400contains two lead in portions like 402 a and 402 b. Further it should beappreciated that in the figure, though the flexible circuit is shown toinclude only two branches, other embodiments of the present inventionmay include more than two such branches, without deviating from thescope of the present invention.

The flexible circuit 400 is shown to include two tail portions 404 a and404 b, two first distended head portions 408 a and 408 b correspondingto the two lead in portions 402 a and 402 b, two second distended headportions 410 a and 410 b corresponding to the two tail portions 404 aand 404 b with help of corresponding coverlay portions 406 a and 406 b.

It should be appreciated that individual elements of the flexiblecircuit 400 are similar in structure, features and functionality to theones defined in conjunction with the flexible circuit 300.

Moving on, FIG. 5 depicts a multiple branched flexible circuit 500 inaccordance with another exemplary embodiment of the present invention,The flexible circuit 500 can form a differential pair when the flexiblecircuit 500 is threaded through a through via. However, it should beappreciated that in other embodiments of the invention other similarelectrical circuits can also be formed without deviating from the scopeof the invention.

The flexible circuit 500 is shown to include two lead in portions 502 aand 502 b through which the flexible circuit 500 is threaded through athrough via. The flexible circuit 500 also includes two tail portions504 a and 504 b. The flexible circuit further includes corresponding twofirst distended head portions 506 a and 506 b and two second distendedhead portions 508 a and 508 b, such that they are connected throughcorresponding coverlay portions 510 a and 510 b.

Also illustrated is a fold line 512, along which the flexible circuit500 may be folded to be converted into a differential pair, while beingthreaded through the through via. However, it should be appreciated thatin other embodiments of the invention other similar arrangement likediscrete electrical components which might be one of, but not limitedto, an active component, an embedded resistance, an embeddedcapacitance, and a fuse can also be formed using the flexible circuit500 without deviating from the scope of the invention.

Again, it should be appreciated that in the figure, though the flexiblecircuit is shown to include only two branches, other embodiments of thepresent invention may include more than two such branches, withoutdeviating from the scope of the present invention. Also, it should beappreciated that individual elements of the flexible circuit 500 aresimilar in structure, features and functionality to the ones defined inconjunction with the flexible circuit 400 and the flexible circuit 300.

Referring to FIG. 6, there are depicted partial portions of threeflexible circuits 600 a, 600 b and 600 c, in accordance with anotherexemplary embodiment of the present invention. The flexible circuits 600a, 600 b and 600 c include first distended head portions 602 a, 602 band 602 c respectively connected to second distended head portions 604a, 604 b and 604 c respectively through coverlay portions 606 a, 606 band 606 c.

In embodiments of the present invention, the coverlay portion 606 a ofthe flexible circuit 600 a may be in form of a looped segment that islooped so as to form a coil as depicted by the coverlay portion 606 b ofthe flexible circuit 600 b or a helix as depicted by the coverlayportion 606 c of the flexible circuit 600 c so as to form a smallinductive portion within the flexible circuit 600 b and the flexiblecircuit 600 c. In an embodiment, the looped portion can be any one of acoil shape, a helical shape and a spiral shape. Further in anembodiment, the at least one looped segment is positioned within the atleast one through via.

The coiled coverlay portion 606 b or the helix coverlay portion 606 care completely housed in the through via through which the flexiblecircuit 600 b or 600 c will be threaded.

In an embodiment, the flexible circuits 600 b or 600 c may be coveredwith a ferrous like material in order to increase the potential value ofthe inductance.

Again, it should be appreciated that individual elements of the flexiblecircuits 600 a, 600 b and 600 c are similar in structure, features andfunctionality to the ones defined in conjunction with the flexiblecircuit 500, the flexible circuit 400 and the flexible circuit 300.

Moving on there is depicted in FIGS. 7 a, 7 b and 7 c different stagesof threading a flexible circuit 700 through a defective through via 702of a printed circuit assembly containing a first contact pad 704 and asecond contact pad 706. A pin hole connector 708 as shown in the figurehelps in interconnection of electrical components in a printed circuitassembly. The pin hole connector 708 runs through the defective throughvia 702 from the first contact pad 704 where electrical components arepresent, to the second contact pad 706. The pin hole connector 708 isshown to be soldered at 710.

The flexible circuit 700 is threaded through the defective through via702 in FIG. 7 b, the flexible circuit 700 is entered from the firstcontact pad 704, through the through via 702, and emerges from thesecond contact pad 706. The flexible circuit 700 is then soldered at thepoint 710 in order to repair the defective through via 702.

Moving on, in FIG. 8 there is depicted an exemplary debug probing device800, in accordance with an embodiment of the present invention. Thedebug probing device 800 can be used for probing a printed circuitassembly without damaging interconnection of electrical componentspresent on the printed circuit assembly. Also, such a debug probingdevice eliminates additional wiring which may be required to be done inorder to connect any conventional debug probing device to the printedcircuit assembly 100.

The debug probing device 800 includes a bulk portion 802 and a pluralityof leader threads like 804 a, 804 b, 804 c, 804 d and 804 e of differentshapes and different sizes. The plurality of leader threads 804 a, 804b, 804 c, 804 d and 804 e may be connected to the flexible circuit 300as depicted in FIG. 3

Some shapes of the leader threads 804 a, 804 b, 804 c, 804 d and 804 emay include, but are not limited to, s-shaped, zigzag shaped, snakeshaped etc. These different leader threads have different advantages andcan help cater to different types of through vias. For example, in anembodiment illustrated by the leader thread 804 e and the bulk portion802, the leader thread 804 e is shown to include a plurality of openings806. The plurality of openings 806 are provided so as to allow clearancefor through vias, surface features or keep out zones.

Moving on there is shown in FIG. 9, an exemplary method of using thedebug probing device 800 on a printed circuit assembly 900. For example,in the depicted method, the leader thread 802 a is inserted through athrough via 902 in order to probe on a surface of the printed circuitassembly 900. If any defect is found in the through via 902 a flexiblecircuit connected to the leader thread 802 a can be threaded in order torepair the defective through via 902.

While the invention has been disclosed in connection with the preferredembodiments shown and described in detail, various modifications andimprovements thereon will become readily apparent to those skilled inthe art. Accordingly, the spirit and scope of the present invention isnot to be limited by the foregoing examples, but is to be understood inthe broadest sense allowable by law.

All documents referenced herein are hereby incorporated by reference.

What is claimed is:
 1. A design and rework device for use in creating inor thru via and repair of a printed circuit assembly, the printedcircuit assembly having at least one through via, the design and reworkdevice being in form of a planar flexible circuit, the planar flexiblecircuit comprising: a lead-in portion at one end of the planar flexiblecircuit, the planar flexible circuit configured to be threaded through aselected one of the at least one through via using the lead-in portion;a tail portion at an opposite end of the planar flexible circuit, thetail portion configured to align the planar flexible circuit on asurface of the printed circuit assembly; a first distended head portionproximal to the lead-in portion; and a second distended head portionproximal to the tail portion, the second distended head portion beingconnected to the first distended head portion by a flex portion, whereina length of the flex portion is substantially equal to a depth of theselected through via, wherein threading of the planar flexible circuitthrough the selected through via positions the first distended headportion on one surface of the printed circuit assembly and positions thesecond distended head portion on an opposite surface of the printedcircuit assembly.
 2. The design and rework device according to claim 1,wherein the printed circuit assembly is a chip to chip interconnectdevice.
 3. The design and rework device according to claim 1, whereinlead-in portion and the tail portion are removable.
 4. The design andrework device according to claim 1, wherein the first distended headportion and the second distended head portion substantially conform totwo ends of the at least one through via.
 5. The design and reworkdevice of claim 1, wherein the design and rework device is laminated,after the threading, to an upper surface of the printed circuit assemblyand to a bottom surface of the printed circuit assembly with at leastone of a pressure sensitive adhesive, a thermoset, and an epoxy.
 6. Thedesign and rework device of claim 1, wherein the design and reworkdevice is coated at least partially with at least one of a nickel basedmaterial, a gold based material, solder leveling, and other metal basedplating.
 7. The design and rework device of claim 1 further comprisingdiscrete electronic components selected from the group of activecomponents, passive components, fuses and combinations thereof.
 8. Therework device of claim 1, wherein a breadth of the flex portion is atleast 0.03 inches.
 9. The rework device of claim 1, wherein a diameterof the distended first head portion and of the distended second headportion is at least 0.01 inches.
 10. The design and rework device ofclaim 1, wherein after the threading, the first distended head portionis laminated to the one surface of the printed circuit assembly and thesecond distended head portion is laminated to the opposite surface ofthe printed circuit assembly using at least one of a pressure sensitiveadhesive, a thermoset, and an epoxy.
 11. The design and rework device ofclaim 1, wherein a result of the threading leaves no perceptibleprotrusion in the printed circuit assembly.
 12. A design and reworkdevice for use in creating in or thru via and repair of a printedcircuit assembly, the printed circuit assembly having at least onethrough via, the design and rework device being in form of a flexiblecircuit, the flexible circuit comprising: at least one lead-in portionat one end of the flexible circuit, the flexible circuit configured tobe threaded through a selected one of the at least one through via usingat least one of the at least one lead-in portion; at least one tailportion at an opposite end of the flexible circuit, the at least onetail portion configured to align the flexible circuit on a surface ofthe printed circuit assembly; at least one first distended head portionproximal to the at least one lead-in portion; at least one seconddistended head portion proximal to the at least one tail portion,wherein the at least one second distended head portion is connected tothe at least one first distended head portion by a flex portion, theflex portion having at least one looped segment, wherein the flexportion is substantially completely housed in the selected through viaafter the threading, such that a result of the threading leaves noperceptible protrusion in the printed circuit assembly.
 13. The designand rework device according to claim 12, wherein the at least one loopedsegment has a shape selected from the group comprising a coil shape, ahelical shape and a spiral shape, further wherein the at least onelooped segment is positioned within the selected through via.
 14. Thedesign and rework device according to claim 12, wherein the printedcircuit assembly is a chip to chip interconnect device.
 15. The designand rework device according to claim 12, wherein the at least onelead-in portion and the at least one tail portion are removable.
 16. Thedesign and rework device according to claim 12, wherein the at least onefirst distended head portion and the at least one second distended headportion substantially conform to two ends of the at least one throughvia.
 17. The design and rework device of claim 12, wherein the designand rework device is laminated, after the threading, to an upper surfaceof the printed circuit assembly and to a bottom surface of the printedcircuit assembly with at least one of a pressure sensitive adhesive, athermoset, and an epoxy.
 18. The design and rework device of claim 12,wherein the design and rework device is coated at least partially withat least one of a nickel based material, a gold based material, solderleveling, and other metal based plating.
 19. The design and reworkdevice of claim 12 further comprising discrete electronic componentsselected from the group of active components, passive components, fusesand combinations thereof.
 20. The rework device of claim 12, wherein abreadth of the coverlay portion is at least 0.03 inches.
 21. The reworkdevice of claim 12, wherein a diameter of the distended first headportion and of the distended second head portion is at least 0.01inches.
 22. A design and rework device for use in creating in or thruvia and repair of a printed circuit assembly, the printed circuitassembly having at least one through via, the design and rework devicebeing in form of a branched circuit having a plurality of branches, thebranched flexible circuit comprising: a plurality of lead-in portions atone end of the planar flexible circuit, wherein a number of theplurality of lead-in portions correspond to a number of the plurality ofbranches, the branched flexible circuit configured to be threadedthrough a selected one of the at least one through via using at leastone of the plurality of lead-in portions; a plurality of tail portionscorresponding to the plurality of lead-in portions, the plurality oftail portions being located at an opposite end of the branched flexiblecircuit and configured to align the branched flexible circuit on asurface of the printed circuit assembly; a plurality of first distendedhead portions corresponding to the plurality of lead-in portions, theplurality of first distended head portions proximal to the plurality oflead-in portions; a plurality of second distended head portionscorresponding to the plurality of tail portions, the plurality of seconddistended head portions proximal to the plurality of tail portions, theplurality of second distended head portions being connected to theplurality of first distended head portions by a flex portion, wherein alength of the flex portion is substantially equal to a depth of theselected through via such that a result of the threading leaves noperceptible protrusion in the printed circuit assembly.